Shawn, Sounds like you have a bad actuator, also called a door motor. Find the source of the clicking and unplug the actuator to verify. The clicking should stop when the electrical plug is out. Use the number on the old part to get the correct part from the dealer. I have a tech article on Jeep HVAC doors that has some information that may apply to Ford’s as well, see the tech article.

Erik, Sounds like the fresh air door also called recirculate door has fallen. This will let outside air enter from behind the glovebox. The image with the dash pulled that has a caption that says “Fresh Air door assembly, broken door fell to the bottom” is what I’m talking about. Drop the glove box door and see if you can see the door moving when switching the controls from normal and max. If you don’t see it moving, it most likely has fallen. Feel through the plastic grate, it’s probably on the bottom, like the one in the picture.

Erik, The method outlined in this blog requires the replacement of the entire fresh air door assembly, since it is not re-usable after it is pulled and broken away from the main case. If you want to use the Napa replacement door that you mentioned, the main evaporator case will need to be pulled which will require much more labor. The point of this tech article is to save a lot of time, but the fresh air door assembly is needed not just the door and it is only available at the Ford dealer. For Ford Explorer and Mercury Mountaneer 2002, 2003, 2004 & 2005 the part # is 1L2Z18B259AC, list price is $49.60, verify application at the dealer.

Erik,

Most likely your recirculating door is broken and lying on the bottom of the assembly. As mentioned previously you can open the glove box and move climate control and see if the door moves. Another way to check if the door is broken is to lift(pry gently) the narrow strip of palstic (insert/tab) located on top of the dash on passenger’s side. Standing outside the vehicle on the passenger’s side look down through the windshield and dash and you can see the door lying on the bottom of the assembly.

Craig, the problem you are describing is most likely a bad actuator – a small electric motor that opens and closes a door to control air flow in the HVAC (Heating Ventilation & Air Conditioning) case. There are several, sometimes they are easy to get to and other times they are buried. If you can access it and verify it is causing the clicking, take the numbers off of it so the dealer can sell you the correct one. Parts stores will not have this part most likely and even the dealers have a difficult time looking up the correct one without the OEM numbers off the old one.

Len, The steering column is only unbolted at the bottom where the shaft connects that goes through the firewall. Leave it attached to the dash.

Nick, Most of the time if the air temperature is noticeable cooler on the passenger side it’s due to the system being a little low on refrigerant. When the broken recirculate door is replaced it will make both sides cooler (because the air will be recirculating), but most likely your system is a little low. You could try topping off the system first to verify this.

Nick, Is it possible the metal heater core that you are describing in the middle is actually the evaporator core? If so it would be normal that it is warm on one side and cooler on the other side.

Is the system fully charged? What are the gauge readings (normal?) and is the inlet to the evaporator ice cold? Vent temperature on Max cold, high setting at 1,000 RPMs?

Todd, when the blower is turned ON, but is not working, use a test light to see if it is getting power and ground. If it is, the blower motor has an intermittant open circuit. – Also try tapping on the blower motor if it’s getting power but not on. If it comes on temporarily this lets you know the motor is failing.

The bulb for the AC switch that flickers could be as simple as the bulb going out or it could mean the control head is acting up.

Sid, if the pressure reading is 50psi with the system off, then it is low on refrigerant. The system should be blowing colder than that, probably more like 50 degrees on max. There’s no heat exchange valve, just an orifice tube (expansion tube). First determine if the system if full and then get an idea from the gauge readings. See our blog on AC gauge readings explained for more info.

To be able to diagnose this properly, it’s important to know both readings. But based on the low side reading being 50psi (ambient temp 90) with the system ON, the system is either 1.Over-charged 2.Not enough air going across the condenser or 3.The compressor is not pumping sufficiently. If you haven’t charged the system recently my guess is the compressor is failing, but again seeing both readings and understanding them is best to diag this problem.

Kiesha, I would first start by hooking up AC gauges and finding out if it is a low refrigerant problem (anti freeze is for the engine’s cooling system not the air conditioning). See our article about AC gauge readings. If the system is low, then check for leaks. Hope that get’s you pointed in the right direction.

Jim, If I were checking your Explorer I’d take a quick look at the recirculate door, then verify the refrigerant charge is full. Somemtimes low refrigerant can cause temp differences from side to side -although I would have thought the passenger side would have been colder than the drivers side if it was low. Then if this is a dual zone system I would use a scan tool to check for codes to see if that would provide any help. It’s always best to rule out the simple things first.

Robert, most likely the cold air coming in behind the glove box is a broken door… there’s only one way to find out and that is to look at it and follow the directions in the blog.

It’s best to check the gauge readings to get an idea what’s going on with the rest of the system, see our auto repair blog “AC gauge Readings Explained.”

Blend doors can cause problems too, but this article is NOT about those (blend door will be in the middle of the dash). This article is about the fresh air door assembly (also called a recirculate door assembly) not the blend door. Be careful when buying after market on this item because you may only get the door and not the assembly. The repair procedure outlined in this blog requires replacement of the housing too, not just the door.

Actuators can of obviously can go bad, but on the Explorer the recirculate door is the weakest part in the HVAC system (therefore the most common failure).

I started this job today. I found everything fine. Now I am stuck trying to unbolt the steering column. I think there are four bolts on a plate by the brake, but I am not sure. Dennis can you guide me or post a picture?
Thanks

Thanks Dennis, I was uncleared if i had to unbolt the steering column, eventhough i read the blog, Then i found the 10mm bolt in the coupler. I took me just a little be more than 3 hours, but the job can be done. Now this baby is blowing and cooling like it should.

Great site, thanks very much. Today I replaced the fresh air door assembly as described above on my 02 explorer. Everything went fairly smooth. The part cost $63 at the local dealer. Realistically this is a 3-4 hour job for a first timer.
Couple of notes/comments that may help those less mechanically inclined like me.
1. No bolts are removed from inside near the steering column – just the one under the cowl trim.
2. Most of the plastic trim adjacent to the dash needs to be removed so the dash can swing out.
3. I unbolted three wiring harnesses from the right side of engine compartment. I don’t know if this is correct.
4. I had to remove two 10mm bolts on each side near the top of the transmission housing behind the center console, in order for the dash to move.
5. In order to remove the center console the top portion of it must be removed, to access four additional 10mm bolts holding the console down.
6. I initially swung the dash out about 6 inches, which was enough to remove the old box, but not enough to fit the new one. I had to wrestle it more on the drivers side to get the extra space to slide the new box down from the top near the windshield.

Hope this helps. Mine works like charm now. Thanks again for the great site.

I would do both. The recirculate door assembly is located behind the glove-box. Read the article above and comments for more information

Checking is easy as stated in the article.
“This can be checked easily. First, listen for increased air flow when changing the the AC to max. If the air doesn’t sound louder in the max position, there’s a good chance the recirculate door is broken. Next open the glove box and look for movement of the recirculate door when switching from normal to max air.”

The recirculate door price can differ depending on your location. If a person is mechanically inclined and willing to read the information provided, the door replacement job can be done saving hundreds of dollars.

I have the same problem…door laying on bottom…so with it covering the blower motor hole, how does the system still blow adequate air on all fan settings?

I have a 2002 Explorer with the door laying at the bottom. Can I just cover the box or somehow block outside air inlet altogether? I don’t need to blend the outside air.

does anyone know the part number for the fresh air door on an 04 explorer

This is great information.
I have the same problem as Mike W. But mine is the center (right) vent and passenger side vent blows warm air. My 2002 xlt control switches are totally different from most since its GCC specs. The left switch has 3 settings for both recirculate and fresh air. The right most switch does not have the max ac setting.

The sound goes louder when setting is on high and there seems to be movement in the recirculate door.

Does it need recharge only? Thanks.

I have a 2002 explorer with rear air. My passenger side air vents blow warmer air than the drivers side. The air in the rear is colder than in the front. The door behind the glove compartment moves when I switch the controls. When checked by my mechanic the system is fully charged. Is there a difference between the door behind the glove box and the blend door? If it is different do I need to remove the dash as described?

Glenn, Yes, there is a difference in the blend door and the recirculate door. The blend door on the Explorer is not a common problem (but anything is possible). I would ask a second opinion from someone locally. Low refrigerant can cause variations of temperature in vents sometimes.

Thanks for the quick response Dennisb. Ill have the ac gauge checked. Its only this last 3 months that my xlt started showing problems since 2002. Service engine soon light problem, dpfe, Courtesy light and now the AC.

Big Thanks for the help – from this side of the world (Dubai)

Matt, no the difference in side to side is not likely because a vacuum leak, unless the door actuators are controlled by vacuum. I would also be looking at the possibilty of low refrigerant or a possible door actuator problem.

Glenn, if the temperature difference is substantial there could be a door or actuator problem like you originally asked. A trained tech that can see exactly what’s going on, should be able pinpoint the problem fairly easily.